Footwear with shaped sole surface

ABSTRACT

The present disclosure provides a footwear having a contoured mid sole, which avoids the need for a separate insole member located within the upper of the footwear. In one embodiment the upper of the footwear includes bottom surface interfaces between the user&#39;s foot and mid sole. The present disclosure also provides related methods of manufacturing.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to provisional application Ser. No. 61/184,648 filed on Jun. 5, 2009 entitled Footwear with Shaped Sole Surface, which is incorporated by reference in its entirety herein.

TECHNICAL FIELD

The present disclosure provides footwear having a contoured foot facing surface and methods of making the same.

BACKGROUND

The upper surface of a mid sole in traditional footwear is typically not specifically contoured to fit a human foot. Instead, a contoured foot bed is typically used to provide the desired fit characteristics. A cross-section of a prior art footwear is shown in FIG. 11. The footwear 10 includes an upper 12 connected above a sole 14. The sole includes a tread portion 16, a mid sole 18, and an insole 20. The upper surface 22 of the mid sole 18 of the depicted prior art configuration is not specifically contoured to fit a person's foot. The upper surface 22 of the mid sole 18 is connected to the bottom surface 24 of the upper 12 (e.g., a board or a slip lasted insole) of the footwear 10. The insole 20, which is contoured to fit against a person's foot is provided in the upper 12 of the footwear 10. The mid sole 18 interfaces between the bottom of the person's foot and the footwear 10 for fit. Improved shoe configurations are desirable.

SUMMARY

The present disclosure provides a footwear having a contoured upper sole surface, which avoids the need for a separate insole member located within the upper of the footwear. In one embodiment the upper of the footwear includes bottom surface interfaces between the user's foot and mid sole. The present disclosure also provides related methods of manufacturing.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a shoe and last according to the principles of the present disclosure;

FIG. 2 is an exploded view of FIG. 1;

FIG. 3 is a cross-sectional view of FIG. 1 along lines 3-3;

FIG. 4 is a perspective view of the last shown in FIG. 2;

FIG. 5 is a side view of the last shown in FIG. 2;

FIG. 6A is a cross-sectional view of the last along line 6A-6A of FIGS. 4 and 5;

FIG. 6B is a cross-sectional view of the last along line 6B-6B of FIGS. 4 and 5;

FIG. 6C is a cross-sectional view of the last along line 6C-6C of FIG. 4;

FIG. 7 is a perspective view of the upper shown in FIG. 2;

FIG. 8 is a longitudinal cross-sectional view of the upper of FIG. 7;

FIG. 9 is a top perspective view of the support member shown in FIG. 2 attached to the sole;

FIG. 10 is a bottom perspective view of the support member shown in FIG. 2; and

FIG. 11 is a cross-sectional view of a prior art shoe with a foot bed insert.

DETAILED DESCRIPTION

Referring to FIG. 1, an embodiment of footwear according to the present disclosure is shown. In the depicted embodiment, the footwear 30 is configured for running on rough, uneven terrain. The footwear 30 includes an upper 32 that is connected above a sole 34. It should be appreciated that the footwear 30, also referred to herein generically and interchangeably as a shoe, could alternatively be of a different type (e.g., dress shoe, basketball shoe, tennis shoe, golf shoe, work boot, hiking boot, hunting boot, running shoe, casual shoe, etc.). Referring to FIG. 1, the footwear 30 is shown with a last 36 positioned within the upper 32. The last 36 is used in the manufacturing process of the footwear and will be described in greater detail below.

Referring to FIG. 2, the arrangement of the components of the footwear 30 is shown in an exploded view. The sole 34 of the depicted embodiment includes an upper surface 38 and a bottom surface 40. In the depicted embodiment, the upper surface 38 is contoured to fit a person's foot. The upper surface 38 is configured to be connected with a bottom portion 50 of the upper 32 of the footwear 30. In the depicted embodiment, the bottom portion 50 of the upper is constructed of a resilient material and is adhered (e.g., cemented) directly to the upper surface 38 of the sole 34. The upper surface 38 and bottom portion 50 are configured to provide some of the functionality of a contoured insole 20, which is also commonly referred to as a foot bed, sock liner, shoe inserts, or inner sole. In other words, the upper surface and bottom portion 50 work with the upper surface 38 of the sole 34 to provide the desired fit features, thereby avoiding the need for a contoured insole 20.

Referring generally to FIGS. 2 and 3, the sole 34 of the depicted embodiment includes mid sole portion 42, a support member 44, a tread member 46, a shock absorbing insert 48, and a heel force distribution member 49. In the depicted embodiment, the upper surface 38 of the mid sole portion 42 defines the upper surface 38 of the sole, and the bottom surface of the tread member 46 defines the bottom surface 40 of the sole 34. The support member 44 is positioned between the tread member 46 and the upper surface 38 of the sole. The support member 44 of the depicted embodiment is configured to provide torsional support as well as force distribution in reaction to point loading in the forefoot area of the footwear 30. In the depicted embodiment, the shock absorbing insert 48 is a gel insert located within the heel area of the sole 34. In the depicted embodiment, the shock absorbing insert 48 is viewable via the bottom of the shoe through a transparent window 70 located in the tread member 46.

Referring to FIGS. 4-6C, the last 36 of the depicted embodiment is shown in greater detail. The last 36 is a form around which the upper 32 of the footwear 30 is constructed. In the depicted embodiment, the last 36 defines the shape of the upper 32. For example, the last 36 defines the geometry of the shoe with respect to the particular heel height, toe shape, and toe spring. In the depicted embodiment the last 36 also has a contoured bottom surface that is configured so that the upper 32 can be formed having bottom surface features that reflect the contours of a foot. In the depicted embodiment, the bottom surface 50 of the upper 32 has contours that reflect the contours on the top surface 38 of sole 34. This construction of the upper 32 using the last 36 with bottom surface contours results in an upper 32 that fits the user without the need for a contoured insole 20. In the depicted embodiment, the inner volume of the upper 32, which is defined by the shape of the last 36, is not sized and configured to receive a contoured insole. However, it should be appreciated that depending on the user's particular foot shape and foot volume, a shoe insert could also be used with the footwear.

The bottom facing surface of the last 36 is contoured in both the lengthwise direction and the widthwise direction. FIG. 6A shows a widthwise cross-section of the last 36 along line 6A-6A of FIGS. 4 and 5. The cross-section shown in FIG. 6A is located at the most raised point on the bottom of the last 36 between the toe end 52 and heel end 54 of the last 36 when the last is viewed from the side as it sits on a horizontal surface (see FIG. 5). The bottom surface of the last at both sides has radiuses R1, R2, which in the depicted embodiment are greater than one-third of an inch. In the depicted embodiment R1 and R2 are both greater than three-eighths of an inch. In the depicted embodiment R1 and R2 are both greater than seven-sixteenths of an inch. In particular, R1 is about a half of an inch and R2 is about four-fifths of an inch.

FIG. 6B shows a widthwise cross-section of the last along line 6B-6B of FIGS. 4 and 5. The cross-section shown in FIG. 6B is located at the widest portion of the last in the heel area of the last 36. The bottom surface of the last at both sides has radiuses R3, R4 which in the depicted embodiment are greater than one-third of an inch. In the depicted embodiment R3 and R4 are both greater than three-eighths of an inch. In the depicted embodiment R3 and R4 are both greater than seven-sixteenths of an inch. In the depicted embodiment R3 and R4 are both greater than two-thirds of an inch. In particular, R3 is about two-thirds of an inch and R4 is about four-fifths of an inch.

FIG. 6C shows a lengthwise cross-section of the last 36 in the heel area along a line 6C-6C of FIG. 4. In the depicted embodiment the heel end has a radius R5 that is greater than three-eighths of an inch. In the depicted embodiment R5 is greater than seven-sixteenths of an inch. In the depicted embodiment R5 is greater than a half of an inch. In the depicted embodiment R5 is greater than five-eighths of an inch. In particular, R5 is about eight-ninths of an inch.

In the depicted embodiment the upper surface 38 of the sole has the same contours as the bottom portion 50 of the upper 32, which are described above. In the depicted embodiment the periphery of the heel area of the upper surface 38 is more curved than the periphery of the forefoot area of the upper surface of the sole 34. It should be appreciated that the above shown and described radiuses of curvature (R1-R5) of the depicted embodiment are representative of the continuous curves in the periphery of the heel area of the upper surface of the sole 34.

Referring to FIGS. 7-8, the upper 32 of the depicted embodiment is shown in greater detail. In the depicted embodiment, the upper 32 is configured to wrap around a person's foot. The upper 32 includes a bottom portion 50 (foot bed portion) that is stitched 58 to a top portion 56. In the depicted embodiment, the bottom portion 50 is constructed of a resilient material. It should be appreciated that the resilient material on the bottom portion 50 facilitates fit as it accounts for variations from one person's foot to the next. In the depicted embodiment the resilient material is a urethane commonly referred to as memory foam. In the depicted embodiment the resilient material has a thickness T1 of between one-eighth to three-eighths of an inch. In the depicted embodiment, a layer of fabric 72 is provided on the bottom surface of the bottom portion 50. The fabric prevents the bottom portion 50 from tearing and facilitates the secure stitched connection between the bottom portion and the rest of the upper 32. A layer of fabric 74 is positioned on the top surface of the bottom portion 50. The fabric 74 wicks moisture from the user's foot and also improves the durability of the bottom portion 50. It should be appreciated that the principles of the present disclosure are compatible with many other alternative upper constructions.

Referring to FIGS. 9-10, the support member 44 of the depicted embodiment is shown in greater detail. In the depicted embodiment, the support member is positioned between the upper surface 38 of the mid sole 42 and the tread member 46. The support member includes a forefoot plate portion 60 positioned between torsion arms 62, 64 that come together in a central body portion 66 extending towards the heel end of the footwear. In the depicted embodiment, the forefoot plate 60 is configured for point load distribution. It distributes force across a larger area of the forefoot than would otherwise result if the person stepped on a small protruding object (e.g., stepping on a marble). The plate includes cut outs that improve flexibility in the longitudinal direction. The torsion arms 62, 64 provide rigidity to prevent undesirable twisting of the footwear. In the depicted embodiment the arms 62, 64 come together in the body potion 66. The body portion includes a window 68 that is aligned with a transparent window 70 in the tread member 46. In the depicted embodiment the shock absorbing insert 48 is viewable through the bottom of the footwear via windows 68 and 70.

The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. It should be appreciated that alternative embodiments may include more or less sole components as well as different sole components. For example, in an alternative embodiment the footwear may not include a separate mid sole portion and tread member, a shock absorbing insert, or a heel force distribution member. The sole could be instead constructed of a single material with a continuous upper contoured surface that is directly attached to the bottom surface of the upper and a bottom surface that is configured to engage the ground surface. As discussed above, the present disclosure is not limited to trail running shoes such as the one disclosed above. The above described alternative sole configuration may, for example, be the sole in a casual shoe. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. 

1. A footwear with a fitted sole comprising: a sole including a bottom surface configured to engage the ground surface and an upper surface having contours thereon that are configured to reflect the contours on the bottom of a person's foot; an upper configured to wrap around a person's foot, the upper including a foot bed portion that is positioned against the upper surface of the sole such that the foot bed portion follows the contours of the upper surface of the sole.
 2. The footwear of claim 1, wherein the foot bed portion is constructed of a resilient material.
 3. The footwear of claim 2, wherein the foot bed portion is constructed of a urethane material.
 4. The footwear of claim 3, wherein the foot bed portion is constructed of a memory foam material.
 5. The footwear of claim 2, wherein the foot bed portion has a thickness of between ⅛ to ⅜ of an inch.
 6. The footwear of claim 1, wherein the sole includes a radiused periphery in the heel portion.
 7. The footwear of claim 1, wherein the radiused periphery has a radius of curvature greater than three-eighths of an inch.
 8. The footwear of claim 1, wherein the radiused periphery has a radius of curvature greater than seven-sixteenths of an inch.
 9. The footwear of claim 1, wherein the radiused periphery has a radius of curvature greater than seven-sixteenths of an inch in the heel area and less than seven-sixteenths in the forefoot.
 10. The footwear of claim 1, wherein a support member is positioned between the top surface of the sole and the bottom surface of the sole.
 11. The footwear of claim 10, wherein the support member includes a forefoot plate portion configured for point load distribution.
 12. The footwear of claim 11, wherein the forefoot portion includes opposed torsion arms that connect in the mid foot portion of the sole and extend towards the rear of the sole.
 13. The footwear of claim 1, wherein the foot bed is adhered to the upper surface of the sole.
 14. The footwear of claim 1, wherein the top surface of the sole in the heel area along the center of the sole is curved at the periphery with a radius of curvature that is greater than seven-sixteenths of an inch.
 15. A footwear with a fitted sole comprising: a sole including a bottom surface configured to engage the ground surface and a contoured upper surface; an upper configured to wrap around a person's foot, the upper including a foot bed portion that is positioned against the upper surface of the sole such that the foot bed portion follows the contours of the upper surface of the sole; wherein the upper is configured to not receive a removable insole.
 16. The footwear of claim 15, wherein the footwear does not include a removable insole positioned above the foot bed within the upper.
 17. A method of manufacturing a footwear comprising: providing a sole with a contoured upper surface; providing an upper with a resilient foot bed portion; connecting the resilient foot bed portion to the contoured upper surface such that the foot bed portion is contoured to fit a person's foot.
 18. The method of claim 17, wherein footwear is constructed without inserting an insole into the upper.
 19. The method of claim 17, wherein the heel portion of the surface of the sole is concaved.
 20. The method of claim 17, wherein the periphery of the heel portion of the upper surface of the sole has a radius of curvature greater than seven-sixteenths of an inch.
 21. The method of claim 17, comprising the step of providing a last into the upper, wherein the last includes a contoured bottom surface. 